PerTronix JBA Exhaust 40-2521 User Manual
Installation instructions, Inst, Part s list

INSTALLATION INSTRUCTIONS
**Inst
**Inst
**Inst
**Inst allation recommendation:
allation recommendation:
allation recommendation:
allation recommendation:
JBA recommends in most cases that the vehicle be taken to a reputable
JBA recommends in most cases that the vehicle be taken to a reputable
JBA recommends in most cases that the vehicle be taken to a reputable
JBA recommends in most cases that the vehicle be taken to a reputable
40-2521
2001 Ford F-150 Super Crew
4.6L, 5.4L 2/4 WD
T OOLS RECOMMENDED:
ratchet
9/16 deep socket
15mm deep socket
channel lock pliers
8mm wrench
rubber mallet
spray lubricant or penetrating oil
pry bar
reciprocating saw or hack saw
2001 Ford F-150 Super Crew
4.6L, 5.4L 2/4 WD
T OOLS RECOMMENDED:
ratchet
9/16 deep socket
15mm deep socket
channel lock pliers
8mm wrench
rubber mallet
spray lubricant or penetrating oil
pry bar
reciprocating saw or hack saw
2001 Ford F-150 Super Crew
4.6L, 5.4L 2/4 WD
T OOLS RECOMMENDED:
ratchet
9/16 deep socket
15mm deep socket
channel lock pliers
8mm wrench
rubber mallet
spray lubricant or penetrating oil
pry bar
reciprocating saw or hack saw
2001 Ford F-150 Super Crew
4.6L, 5.4L 2/4 WD
T OOLS RECOMMENDED:
ratchet
9/16 deep socket
15mm deep socket
channel lock pliers
8mm wrench
rubber mallet
spray lubricant or penetrating oil
pry bar
reciprocating saw or hack saw
A. Head pipe
1
B. Muffler
1
C. Tail pipe
1
D. Turn out
1
E. 2-1/2" clamp
1
F. 3" clamp
1
G. 3" clamp/hanger
1
H. 3" clamp
1
A. Head pipe
1
B. Muffler
1
C. Tail pipe
1
D. Turn out
1
E. 2-1/2" clamp
1
F. 3" clamp
1
G. 3" clamp/hanger
1
H. 3" clamp
1
A. Head pipe
1
B. Muffler
1
C. Tail pipe
1
D. Turn out
1
E. 2-1/2" clamp
1
F. 3" clamp
1
G. 3" clamp/hanger
1
H. 3" clamp
1
A. Head pipe
1
B. Muffler
1
C. Tail pipe
1
D. Turn out
1
E. 2-1/2" clamp
1
F. 3" clamp
1
G. 3" clamp/hanger
1
H. 3" clamp
1
B
A
D
E
C
F
G
H
Part s List
B
A
D
E
C
F
G
H
Part s List
B
A
D
E
C
F
G
H
Part s List
B
A
D
E
C
F
G
H
Part s List
anti-seize
anti-seize
anti-seize
anti-seize
T
T
T
T O
O
O
O ST
ST
ST
ST ART
ART
ART
ART ::::
2. Disconnect negative battery cable and
2. Disconnect negative battery cable and
2. Disconnect negative battery cable and
2. Disconnect negative battery cable and
allow vehicle exhaust to cool.
allow vehicle exhaust to cool.
allow vehicle exhaust to cool.
allow vehicle exhaust to cool.
1. Remove and inventory new Evol
1. Remove and inventory new Evol
1. Remove and inventory new Evol
1. Remove and inventory new Evol
exhaust.
exhaust.
exhaust.
exhaust.
8. Using some form of heat and force,
8. Using some form of heat and force,
8. Using some form of heat and force,
8. Using some form of heat and force,
remove muf
remove muf
remove muf
remove muffler assembly t
fler assembly t
fler assembly t
fler assembly taking care not
aking care not
aking care not
aking care not
to damage front head pipe.
to damage front head pipe.
to damage front head pipe.
to damage front head pipe.
12. Slip muf
12. Slip muf
12. Slip muf
12. Slip muffler hanger (G) over end of
fler hanger (G) over end of
fler hanger (G) over end of
fler hanger (G) over end of
muf
muf
muf
muffler (B)) and hand tighten only at
fler (B)) and hand tighten only at
fler (B)) and hand tighten only at
fler (B)) and hand tighten only at
this time.
this time.
this time.
this time.
17. With t
17. With t
17. With t
17. With tail pipe properly aligned, tighten
ail pipe properly aligned, tighten
ail pipe properly aligned, tighten
ail pipe properly aligned, tighten
rear muf
rear muf
rear muf
rear muffler clamp/hanger (G) completely
fler clamp/hanger (G) completely
fler clamp/hanger (G) completely
fler clamp/hanger (G) completely
3. With vehicle raised and properly
3. With vehicle raised and properly
3. With vehicle raised and properly
3. With vehicle raised and properly
supported, using a reciprocating saw
supported, using a reciprocating saw
supported, using a reciprocating saw
supported, using a reciprocating saw
or hack saw
or hack saw
or hack saw
or hack saw, cut the t
, cut the t
, cut the t
, cut the tail pipe approx.
ail pipe approx.
ail pipe approx.
ail pipe approx.
3î behind muf
3î behind muf
3î behind muf
3î behind muffler
fler
fler
fler. See notes #1
. See notes #1
. See notes #1
. See notes #1
with 9/16" deep wall socket.
with 9/16" deep wall socket.
with 9/16" deep wall socket.
with 9/16" deep wall socket.
NOTE:
NOTE:
NOTE:
NOTE:
Use
Use
Use
Use
anti-seize on all threads of clamp. See
anti-seize on all threads of clamp. See
anti-seize on all threads of clamp. See
anti-seize on all threads of clamp. See
note #2.
note #2.
note #2.
note #2.
4. S
4. S
4. S
4. Spray lube on rear t
pray lube on rear t
pray lube on rear t
pray lube on rear tail pipe hanger rod
ail pipe hanger rod
ail pipe hanger rod
ail pipe hanger rod
and remove from lower hole in rubber
and remove from lower hole in rubber
and remove from lower hole in rubber
and remove from lower hole in rubber
grommet using channel lock pliers.
grommet using channel lock pliers.
grommet using channel lock pliers.
grommet using channel lock pliers.
5. Remove t
5. Remove t
5. Remove t
5. Remove tail pipe assembly from
ail pipe assembly from
ail pipe assembly from
ail pipe assembly from
rear of vehicle.
rear of vehicle.
rear of vehicle.
rear of vehicle.
9. Inst
9. Inst
9. Inst
9. Install head pipe (A), aligning notch
all head pipe (A), aligning notch
all head pipe (A), aligning notch
all head pipe (A), aligning notch
with locating pin.
with locating pin.
with locating pin.
with locating pin. Y
Y
Y
You may have to t
ou may have to t
ou may have to t
ou may have to tap it
ap it
ap it
ap it
on using a rubber mallet.
on using a rubber mallet.
on using a rubber mallet.
on using a rubber mallet.
13. Inst
13. Inst
13. Inst
13. Install 2-1/2" clamp (E) over front slip
all 2-1/2" clamp (E) over front slip
all 2-1/2" clamp (E) over front slip
all 2-1/2" clamp (E) over front slip
joint on head pipe (A). Position so clamp
joint on head pipe (A). Position so clamp
joint on head pipe (A). Position so clamp
joint on head pipe (A). Position so clamp
is on rear side of locating pen as close as
is on rear side of locating pen as close as
is on rear side of locating pen as close as
is on rear side of locating pen as close as
possible and tighten completely using a
possible and tighten completely using a
possible and tighten completely using a
possible and tighten completely using a
9/16" deep wall socket.
9/16" deep wall socket.
9/16" deep wall socket.
9/16" deep wall socket.
NOTE:
NOTE:
NOTE:
NOTE:
Use anti-
Use anti-
Use anti-
Use anti
seize on threads of clamp. See note #2
seize on threads of clamp. See note #2
seize on threads of clamp. See note #2
seize on threads of clamp. See note #2
14. Inst
14. Inst
14. Inst
14. Install 3" clamp (F) over front muf
all 3" clamp (F) over front muf
all 3" clamp (F) over front muf
all 3" clamp (F) over front muffler
fler
fler
fler
slip joint and position 1/4" from lip.
slip joint and position 1/4" from lip.
slip joint and position 1/4" from lip.
slip joint and position 1/4" from lip.
T
T
T
Tighten completely with 9/16" deep
ighten completely with 9/16" deep
ighten completely with 9/16" deep
ighten completely with 9/16" deep
socket.
socket.
socket.
socket.
NOTE:
NOTE:
NOTE:
NOTE:
Use anti-seize on
Use anti-seize on
Use anti-seize on
Use anti-seize on
threads of clamp. See note #2.
threads of clamp. See note #2.
threads of clamp. See note #2.
threads of clamp. See note #2.
18. Inst
18. Inst
18. Inst
18. Install turn out (D) over end of t
all turn out (D) over end of t
all turn out (D) over end of t
all turn out (D) over end of tail pipe
ail pipe
ail pipe
ail pipe
(C) and rot
(C) and rot
(C) and rot
(C) and rotate to desired position leaving
ate to desired position leaving
ate to desired position leaving
ate to desired position leaving
clearance from body
clearance from body
clearance from body
clearance from body....
6. With muf
6. With muf
6. With muf
6. With muffler supported, spray lubricant
fler supported, spray lubricant
fler supported, spray lubricant
fler supported, spray lubricant
on rear muf
on rear muf
on rear muf
on rear muffler hanger rods and remove
fler hanger rods and remove
fler hanger rods and remove
fler hanger rods and remove
from lower holes in rubber grommet
from lower holes in rubber grommet
from lower holes in rubber grommet
from lower holes in rubber grommets
s
s
s
using channel lock pliers.
using channel lock pliers.
using channel lock pliers.
using channel lock pliers.
7.
7.
7.
7. S
S
S
Spray lubricant on front muf
pray lubricant on front muf
pray lubricant on front muf
pray lubricant on front muffler clamp
fler clamp
fler clamp
fler clamp
and remove using a 15mm socket
and remove using a 15mm socket
and remove using a 15mm socket
and remove using a 15mm socket
1
1
1
11. Inst
1. Inst
1. Inst
1. Install muf
all muf
all muf
all muffler (B) with JBA logo
fler (B) with JBA logo
fler (B) with JBA logo
fler (B) with JBA logo
towards rear of vehicle.
towards rear of vehicle.
towards rear of vehicle.
towards rear of vehicle.
10. Inst
10. Inst
10. Inst
10. Install rear 3" muf
all rear 3" muf
all rear 3" muf
all rear 3" muffler clamp/hanger
fler clamp/hanger
fler clamp/hanger
fler clamp/hanger
(G) through lower holes in rubber grom-
(G) through lower holes in rubber grom-
(G) through lower holes in rubber grom-
(G) through lower holes in rubber grom
met
met
met
mets with longer rod towards driver
s with longer rod towards driver
s with longer rod towards driver
s with longer rod towards driveríííís side.
s side.
s side.
s side.
15. Inst
15. Inst
15. Inst
15. Install t
all t
all t
all tail pipe (C) from rear of vehi-
ail pipe (C) from rear of vehi-
ail pipe (C) from rear of vehi-
ail pipe (C) from rear of vehi
cle and slip into rear of muf
cle and slip into rear of muf
cle and slip into rear of muf
cle and slip into rear of muffler (B).
fler (B).
fler (B).
fler (B).
NOTE:
NOTE:
NOTE:
NOTE:
Make sure that the end of the
Make sure that the end of the
Make sure that the end of the
Make sure that the end of the
ttttail pipe with the hanger rod is at the
ail pipe with the hanger rod is at the
ail pipe with the hanger rod is at the
ail pipe with the hanger rod is at the
rear of vehicle.
rear of vehicle.
rear of vehicle.
rear of vehicle.
16. Inst
16. Inst
16. Inst
16. Install rear t
all rear t
all rear t
all rear tail pipe hanger into lower
ail pipe hanger into lower
ail pipe hanger into lower
ail pipe hanger into lower
hole of rubber grommet. Rot
hole of rubber grommet. Rot
hole of rubber grommet. Rot
hole of rubber grommet. Rotate t
ate t
ate t
ate tail pipe
ail pipe
ail pipe
ail pipe
(C) to align rear hanger rod.
(C) to align rear hanger rod.
(C) to align rear hanger rod.
(C) to align rear hanger rod.
20. Retighten all clamp
20. Retighten all clamp
20. Retighten all clamp
20. Retighten all clamps and t
s and t
s and t
s and tack weld all
ack weld all
ack weld all
ack weld all
slip joint
slip joint
slip joint
slip joints.
s.
s.
s.
21. Lower vehicle and reatt
21. Lower vehicle and reatt
21. Lower vehicle and reatt
21. Lower vehicle and reattach the
ach the
ach the
ach the
negative battery cable.
negative battery cable.
negative battery cable.
negative battery cable.
NOTES:
NOTES:
NOTES:
NOTES:
1.
1.
1.
1. If vehicle is raised with proper vehicle
If vehicle is raised with proper vehicle
If vehicle is raised with proper vehicle
If vehicle is raised with proper vehicle
lif
lif
lif
lift, step #3 can be eliminated and stock
t, step #3 can be eliminated and stock
t, step #3 can be eliminated and stock
t, step #3 can be eliminated and stock
exhaust can be removed in one piece
exhaust can be removed in one piece
exhaust can be removed in one piece
exhaust can be removed in one piece
2.
2.
2.
2. If anti seize is not used on threads of
If anti seize is not used on threads of
If anti seize is not used on threads of
If anti seize is not used on threads of
clamp
clamp
clamp
clamps before tightening, the nut's will
s before tightening, the nut's will
s before tightening, the nut's will
s before tightening, the nut's will
gall,
gall,
gall,
gall, and clamp rod will break.
and clamp rod will break.
and clamp rod will break.
and clamp rod will break.
19. Inst
19. Inst
19. Inst
19. Install 3" clamp (H) over turn out slip
all 3" clamp (H) over turn out slip
all 3" clamp (H) over turn out slip
all 3" clamp (H) over turn out slip
joint and position 1/4î from lip.
joint and position 1/4î from lip.
joint and position 1/4î from lip.
joint and position 1/4î from lip. T
T
T
Tighten
ighten
ighten
ighten
completely using 9/16" deep socket.
completely using 9/16" deep socket.
completely using 9/16" deep socket.
completely using 9/16" deep socket.
NOTE:
NOTE:
NOTE:
NOTE:
Use anti-seize on all threads of
Use anti-seize on all threads of
Use anti-seize on all threads of
Use anti-seize on all threads of
clamp. See note #2
clamp. See note #2
clamp. See note #2
clamp. See note #2
W
W
W
We
e
e
e recommend taking the truck to a muffler shop and having all slip connections tack welded.
recommend taking the truck to a muffler shop and having all slip connections tack welded.
recommend taking the truck to a muffler shop and having all slip connections tack welded.
recommend taking the truck to a muffler shop and having all slip connections tack welded.